Molding



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MOLDING Filed Oct. 25, 1926 13 Sheets-Sheet l1 June 18, 1929. D. J. CAMPBELL 1.717.914

MOLDING Filed Oct. 25, 1926 13 Sheets-Sheet 12 t* lnuwov v Momag;

June 18, 1929. D, J; CAMPBELL .1.717.914

MOLDING Filed 001'.. 25, 1926 13 Sheets-Sheet 13 Patented .lune 18, 1929.

UNETED STATES DONALD J'. CAMPBELL, MUSKEGON HEIGHTS, MICHIGAN.

MOLDING.

Application filed October 25, 1926. Serial No. 143,917.

rll`his invention relates to improvements in the method and apparatus for making molds 'lor castings and particularly for cored castings such as cylinder block castings for internal conibustion engines and the like.

In the Afollowing description the invention is described as applied to a casting for a water jacketed multiple cylinder block Which includes valve chan'lbers, valve tappet chambers, inlet and exhaust passages and the upper portion of the crank case of the engine all `lormed as au integral casting. The making et' the mold tor a casting of this description i a typical example oft the utilization of this invention but it is to be understood that the invention may also be employed in making molds for castings ot other descriptions.

The so called cylinder block casting et a modern multiple cylinder Water jaeketed internal combustion engine is one of the most complicated in common commercial use and it has heretofore been the common practice in makin the mold for such a casting to utilize a great many so called dry sand cores. In the vernacular ot the foundry a mold may be composed partly et green sand and partly ot dry sand cores. The green sand is the ordinary melders sand which is pressed or tamped in a flask around the pattern and retains its shape by the natural tendency of molding sand particles to cling together and this type oit mold must be handled carefully and has no great strength. The dry sand cores are formed ot a dillerent kind of sand usually mixed with linseed oil and some other ingredients and firstmolded to shape in a term called a core box after which they must he baked and they may then be readily handled and placed in the green sand mold in their proper ,lo-ations.

llhere a casting is of such shape that its mold may bc Wholly or largely formed ot' green sand the molding is comparatively simple and inexpensive but Where the mold necessitates the large use of dry sand cores the expense ,is largely increased. The reason for this is that in the first place the forming of a green san d mold is much more simple than that ot' a dry sand core. It constitutes only the one act oit con'ipressing the sand in the i l ask around the pattern. llVhile in the manuiliaeture olf the dry sand core the materials must lirst be mixed and then molded in a separate core box after which they must be baked in an oven and then properly located in the mold, `fr"withermore 'the green. sand may be used over and over with little loss or expense While it is not practical to use the dry sand core more than once7 it being customary to discard the dry sand core after the casting has been made and provided new core sand which in itselit' is of considerable expense and the ingredients which are mixed With it are also expensive when considered on a basis of large production.

The principal object ot this invention is to provide means for dispensing to a large extent With dry sand cores, replacing those parts of the mold ivith forms of green sand. Another object of the invention is to provide a most convenient and economical method and apparatus for forming the different parts ot the mold ot'xgreen sand. The invention also provides various means for strengthening and support-ing the green sand portions of the mold in such a Way that the green sand may be used Where heretofore .it has been considered necessary to use dry sand cores. Various otherI novel features pertaining to the formation of the mold and the apparatus therefor are also included in the invention as are hereinafter more fully described and particularly pointed out in the claims, reference being had to the accon'ipanying drawing in which:

Fig. l is a plan view of a cylinder' block casting, with parts broken away, such as may be cast in a mold formed by means of this invention.

Fig. 2 is a side elevation of the same with a portion broken aivay.

Fig. 3 is an elevation of one end of the casting.

Fig. l is a transverse sectional elevation sustantially on the line fl-t oli' Fig. 2.

F ig. 5 is a transverse sectional elevation on the line 5-5 of Fig. 2.

Fig. 6 is a transverse sectional elevation on line 6*(3 ot Fig. 9 showing the riser and branch the-reel used for pouring.

Fi 7 is a transverse sectional elevation of the various parts ot the green sand mold shown in partially separated position.

Fig. 8 is a transverse sectional elevation of the complete mold with the metal cast therein.

Fig. 9 is a fragmentary longitudinal sectional elevation of the same.

Fig. 1() is a horizontal section of one end of the mold on the line lO-lO ot Fig. 8.

Fig. 11 lis a horizontal section of one end el? the meld on the line 11e-1.1. en? 8.

Ll O

Fig. 14 is a tragn'ieutary longitudinal section through the pattern for forming the drag portion oi"- the inold showing the drag iiask and parts oit a niolding niachine in posi' tion.

Fig. 15 is a transverse sectional elevation ot the same.

Fig. 16 is a transverse sectional elevation of the cheek portion otl the inold in its ltirst stages of 4formation and includes parts of the apparatus used therefor.

Fig. l'shows the saine at the completion of its torination with parts ot t-he apparatus used.

Fig. 18 is a horizontal section ot' one end of the inold and apparatus as shown in Fig. 16 on the line 18%18 ot Fig. 16.

Fig. 19 is a perspective View of the coinpleted cheek portion oi the inold.

Fig. 20 is a perspective vieiv of the green sand tappet chainher eore.

Fig. 21 is a transverse section ol'I the pattern and other apparatus used .tor 'lorining the tappet ohainher core shown inthe lirst stages of formation.

Fig, 22 is the. saine at the eoinpletion ot the operation.

Fig. 23 is a horizontal section of one end of the saine on the line 23-23 of Fig. 22.

Fig. 211 is a. transverse sectional elevation et the pattern and apparatus for 'forming the cope portion of the inold before the sand has heen squeezed.

Fig. 25 is an inverted plan view oiE the cylinder' barrel iillingl and vent pipe locating gauge which is a part ot the apparatus used with this invention.

Fig. 26 is a transverse sectional elevation ot' the said gauge in use to [ill the cylinder barrels of the pattern, and

Fig, 27' is the saine showing the gauge in position to guide the vent pipes.

' Like reference characters refer to like parts in the different Figures ot' the drawings.

1 represents the casting shown in the aecon'ipanying drawings as an example of the pieee to he cast by use oi' this invention. This casting` has six cylinders 2 open at top and bottoni and surrounded at their upper portions by a Water jacket 3. Valve ehani hers 4 tor the inlet and exhaust valves are also provided and passages 5 communicates Wit-h these chambers. The valve chambers and passages are surrounded as inueh as possible hy the said Water jacket 3. The casting includes the upper part of the crank ease 6 which is substantially semi-cylindrical in shape and hearing supports 7 are provided at each end of the casting and a. central hearing support 8 is also provided. The central hearing support 8 is cored hollow for lightness and the ends of the casting have flanges 9 and 10 to which othei` parts of the engine are attached. rlhese ends are strengthened by webs such as shown at 11. A valve tappet chainher 12 is pro-vided at one side ot the east-.ing beneath the valve ehainhers, this ehainher extending substantially the entire length ot the casting andopening at one side thereof, this opening being divided by a dividing rail 13. The bottoni of the valve tappet elianilier has a plurality ot holes 111 ezitei'iding` through into the crank ease through which the valve tappets of the engine pass. As previously stated this casting providing all ot the ports, chambers. pas sages, etc. is ez .st integrally.y Y

The inold tor the casting eoniprises essentially the drag 15, the cheek 1G, the cope 1f? and the tappet chamber inold 18.

The drag pattern 19 for forming the drag inold preferablyr inounted on a inolding machine of suitable type which includes a. squeezing inenilier 20, a pressure head 21 and a stripping tahle 22, as shown in Figs, 14 and 15. This part ot the lnold is torn'ied upside down, the drag lask 23 heilig supported hy the stripping table during the operation. 1With the flask in position over the pattern the pattern and flask are tilled with sand and jolted in the usual Way and the squeezing nieniher 2O and stripping table 22 are then raised in unison against the pressure head 21 to compress the sand in the inold and flask, aiter which the squeezing ineinher 2O carrying thepattern is lowered during vibration lot the inold While the stripping table reinains stationary to separate the pattern .troni the inold and the completed drag` portion ot the inold is then inverted and placed in position shoivn in Fig. 8. V

rllhe drag pattern inakes the impression for the center hearingv support 8 and this hearing support has extensions 8a which must he provided for in the pattern as follows: The sulistantially seini-cireular loose pieces 24 are laid in the pattern. and the sand is inolded around thein and when the pattern is Withdran'n these loose pieces separate vtroni the pattern and remain in the sand until the patn i (LS vtern has nioved away 'from them whereat theyT will inove inwardly and drop iroin the inold tl'irough the iinprint made by the pat'- tern. The flask 2B is llnovided with integrally itornied Weir-4 25 entendin into the sand to i strengthen and support it, these webs being so shaped that they are completely surrounded hy the sand and cannot contact with thel inetal ot the casting when it is poured intoV the inold. As the niold is niuch deeper 'in its center portieri than at the edges a block 2G is attached to the surface oit the pressure head 21 to imprint the sand at the deep portion oit the inold to insure its proper packinf and the Webs 25 are out aivay atv the center to receive the block 26. The block 26 makes the l il) imprint. 27 in the under surface of the mold which interferes in no way with the casting.

rfhe cheek mold forms that part of the pattern which molds the outside of the casting from the hase to the approximate center ofthe water jackets, being cut away at its front por tion for the reception of the tappet chamber mold. This cheek mold is preferably formed by use of a molding machine having a squeezing member 28. a stripping table 29 and pressure head 30 and the pattern comprises two portions, the lower portion 3l of which is mounted on the squeezing member 28 and the upper portieri 32 is attached to the pressure head 30. The flask 33 for this mold has a recess 34 in its front wall for the reception of the tappet chamber mold. In making this mold the flask 33 is supported upon the strip ping table 2f) and a so-called dummy 35 is placed over the flask, this dummy covering the top of the lower portion of the pattern 31 and also extending down into the recess 35 of the flask. The dummy is guided to proper position by the guide pins 3G on the lower portion of the pattern. Sand is deposited in the flask around the pattern through openings in the top of the dummy and is then jolted in place after which the superfluous sand is scraped off from the top of the dummy and the dummy removed and the squeezing member and stripping table are raised in unison against the pressure head 30 to which is attached the upper portion of the pattern 32 and the same is pressed tightly in the mold around the pattern. The upper portion of the pattern 32 forms the recess in the mold for the reception of a tappet chamber mold and also the imprint for the lower part of the water jacket. After the squeezing operation the squeezing member 28 and stripping table 29 are lowered to separate the two parts of the pattern. and remove the upper part from the mold and the squeezing member 28 carrying the lower part of the pattern is then lowered while the stripping table 29 is held stationary withdrawing the lower part of the pat-tern from the mold. `The mold is then removed and placed upon the drag mold, as shown in Fig. 6. The flask 33 is provided with webs 37 which extend into the sand to aid in holding it in place. y

The tappet chamber mold is formed about a so-called arbor which has a vertical face 38 the proper size to fill in the aperture 84 in the front side of the cheek flask. From the rear of this plate 38 a structure of supporting members 39 extends, about which the sand is pressed to iorm the mold. This supporting structure is so shaped that it will be wholly covered by the sand of the mold and not be contacted by the metal of the casting.

This mold is preferably formed by use of a molding machine as shown in Figs. 21, 22 and 28? thepattern comprising a bottom portion 40, the vertical'portion 41k and the top portion 42. The bottom 40 of' the pattern is supported by the squeezing member 43 of the machine, the vertical portion 41 is carried by the stripping` table 44 of the machine and the top portion 42 is mounted on the squeezing head 45. In addition to these members a prong 46 fixed to the stripping table 44 extends upward through the bottoni portion 4() of the pattern and forms an opening through the mold into which the molten iron runs in casting to form the dividing strip 18 in the center of the opening of the tappet chamber.

In' forming this portion ot the mold the arbor is supported 'upon the lower portion 40 of the pattern and the sand is deposited within the pattern and olted and scraped oll"7 as shown in Fig. 2l. rlhe sand is then squeezed by the head which also carries the upper portion 42 of the pattern7 as shown in Fig. 22. The mold is then drawn away from the head 45 and the stripping table 44 is lowered to draw .the vertical portion 4l of' the pattern and also the prong 46 away from the sand after which the arbor with the sand molded around it is withdrawn and placed in position7 as shown in llig. 8.

The cope mold is formed as shown in Figs. 24, 25, 26 and 27 by the aid of a molding machine of suitable type. The cope mold forms the upper part of the casting above the substantial center of the water jackets and also has the downwardly extending barrel cores which mold the cylinders of the casting7 these barrel cores being formed integrally with the cope mold el? green sand. The pattern for the cope mold comprises the central portion 47 which is mounted on the stripping table 48v of the molding machine and the outer portion 49 which is mounted on the squeezing member 50 of the molding machine. The plungers 5f which close the lower ends of the barrel portions ot the pattern are mounted on the squeezing member 50. The first operation in forming this mold is the filling of the` barrels 52 with sand and then locating the vent pipes 53 therein.

A filling measure and centering gauge 54 is utilized for this part of the operation, this device comprising a plate having six measuring ein s 55 to correspond with the numbers of barrels to be filled with sand. rlhe plate is also provided with stop gauges 5G and 57 which engage the pattern and properly locate it thereon. The device is also provided with properly positioned guide holes 58 through which the vent pipes are inserted. In using this device the measuring cuis 55 are first filled with sand and they are then inverted over the barrels 52 of the pattern and the plate of the device is laid upon the top surface of the pattern and the guide stops 56 are brought into engagement with one edge FII of the pattern. In this position the sand in the cups 5() is deposited in the barrels and the device is then moved until the stops 57 engage'the opposite side of the pattern which properly locates the `holes 58 over the barrels so that the vent pipes 53 may be inserted therethrough and imbedded in the sand to properly position them in the center of the respective barrels.

The measuring and centering device is then removed and the flask 59 is located upon the pattern and filled with sand and jolted and the sand is then squeezed by bringing the flask and pattern upward toward the squceaing head G0. rlhe pattern is removed from the mold by lowering the stripping table itl which lowers the center part of the pattern, the plungers 5l remaining stationary to support the barrel cores during this stripping operation. After the center portion Llei' of the pattern has been thus removed from the sand the cope mold with the depending barrel cores is placed in position over the cheek mold and tappet chamber mold, as shown in Fig. 8. rlhe cope mold also provided with a structure of webs (Sl. and cylindrical members 6&2 imbedded in the sand and wholly surrounded thereby toV support the sand vin place in the flask.

'lhe water jacket core G3 and the cores for the valve chambers and passages Get must be made of dry sand, their shape and location being such that it is impossible to form and support them if made of green sand. These dry sand cores are located upon the cheek and tappet chamber molds before placing the cope mold.

The hollow portion of the center bearing support S is formed by a dry sand core G5 located and supported in the usual .way and the ends of the casting around the bearing supports 7 are also formed by dry sand cores 66, the core prints therefor having been formed in the cheek mold. A riser 67 which extends vertically through the sand at one end of the cheek mold is branched at its lower end to communicate with gates G8 provided in the drag mold. These gates join the casting by sprues 69 extending at intervals therefrom. The usual strainer cores 68L1 are provided at the ends of the gates through which the iron passes. To facilitate pouring the iron the riser 67 extends horizontally at G7 in the cope mold and thence upwardly at (3'7" near one corner of the flask. Inasmuch as the flask is quite large it is desirable to have the pouring opening near one corner or one edge where it is more accessible.

By use of this invention as described the molding of the complicatedv cylinder block casting is greatly simplified and cheapened. It will be seen that the mold comprises the four major parts and viii-addition a comparatively very few dry sand cores. Many parts of the mold, especially the cylinder barrel cores and the tappet chamber cores, may be made of green sand by this invention where heretofore it was necessary to use dry sand cores. The formation of the separate parts of the mold of green sand by use of the patterns constructed as described, is much more simple than has heretofore been done.

When the mold is assembled the inner part of the tappet chamber mold is supported by projections 70 on its under surface which engage like projections 71 on the upper surface of the drag mold, these projections serving as cores to form the holes 14 in the bottom of tapped chamber. The lower ends of the barrel cores engage and are supported by the top of the drag mold and these barrel cores are also strengthened by the vent pipes 53 which extend through them.

The patterns are accurately made and the flasks are positioned relative to each other by the usual guide pins so that when assembled the mold is very accurate as to measurement and fit and the resulting casting is very nearly perfect in dimensions.

In a foundry where a large production of a single type of casting is .made the saving by the use of this invention is very large,

this saving including not only the saving of materials by substituting the green sand cores as much as possible by the dry sand cores, as previously described, but the molds may be made much more rapidly and consequently a much larger product-ion may be had resulting in a saving in labor and generalv overhead expenses.

I claim:

1. A moldfor castings comprising a drag portion, a cheek portion having a lateral recess extending through a vertical side thereof, a portion adapted to b-e inserted in said lateral recess to fill the same and extending into the mold cavity, and a cope portion.

2. A mold for castings formed of green sand having a recess in a vertical side thereof, a flask for the same having a corresponding recess in a vertical side thereof, and an arbor plate detachably mounted in said recess in the flask and having a portion of the mold formed thereon and extending into said recess in the mold.

3. A mold for castings formed of green sand having a recess in a vertical side lthereof, a flask for the same having a corresponding recess in a vertical side thereof, an arbor plate to be detachably located vin the said. recess in the vertical side of the flask and a green sand core formed on the said arbor plate and extending into said recess in the mold and supported by said mold at its inner end. Y

l. A mold for cylinder block castings comprising a drag portion to forni the under and inner sides of the lower part of the casting, a cheek mold to form the outer sides of the major portion of the casting, said meld llO lli

having a recess in one side thereof, a tappet chamber core made of green sand located in said recess in said cheek mold, and a cope mold having depending green sand cores to term the cylinders of said casting.

5. A mold for cylinder block castings comprising a drag portion to i'orm the under and inner sides of the lower part of the casting, a cheek mold to form the outer sides of the major portion of the casting, said cheek mold having a recess in one side thereof, a tappet chamber core made oi green sand located in said recess in said cheek mold, and a cope mold having depending green sand cores to form the cylinders of said casting, said depending cores engaging and supported by said drag mold.

G. A mold for cylinder block castings comprising a drag portion to iorm the under and inner sides of the lower part of the casting, a cheek mold to form the outer sides of the ma- `ior portion of the casting, said cheek mold having a recess in one side thereof, a tappet chamber core made oi green sand located in said recess in said cheek mold, a cope mold having depending green sand cores to form the cylinders of said casting, and vent pipes embedded in said depending cores to strengthen and vent the same.

7. A mold for cylinder bleek castings comprising a drag portion to form the under and inner sides oit the lower part of the casting, a cheek mold to form the outer sides of the maj or portion of the casting, said cheek mold having a recess in one side thereof, a tappet chamber core made of green sand located in said recess in said Acheek mold, a cope mold having depending green sand cores to form the cylinders of said casting, said depending cores engaging and supported by saidI drag mold, and vent pipes embedded in said cores to strengthen and vent the same.

8. A mold for cylinder block castings eemprising a diag portion to form the under and inner si des of the lower portion oi the casting, a cheek portion to form the outer sides of the major portion of the casting, said cheek portion having a recess therein, a tappet chamber core made of green sand located in the said recess in the cheek portion, projections near the inner end of said tappet chamber core engaging the drag portion, and a cope portion having depending cores made of green sand to form the cylinders.

9. A mold for cylinder block castings comprising a drag portion, a cheek portion having a lateral recess in a vertical side in its upper surface, a tappet chamber core made of green sand located Within said lateral recess, dry sand cores supported by said cheek portion and said tappet chamber core, and a cope portion.

10. A mold for cylinder block castings comprising a drag portion, a cheek portieri having a tLateral recess in a vertical side open at its upper surface, a tappet chamber core made oft green sand located within said lateral re cess, dry sand cores .supported by said cheek portion and said tappet chamber core, and a cope portion having depending green sand cores engaging and supported by said drag portion.

l1. A mold lor castings having a recess and surrounded by a flask having a corresponding recess, an arbor plate detachably located in said recess in the flask, supporting members extending from said arbor plate, and a green sand core formed about said supporting members and supported thereby and located Within the said recess in the mold.,

l2. A mold for castings having a recess and surrounded by a flask having a corresponding recess, an arbor plate detachably located in said recess in the flask, supporting members extending from said arbor' plate, and a green sand core formed about said supporting members and supported thereby and located Within the said recess in the mold, said core engaging with said mold near its inner edge Whereby it is supported.

In testimony Whereoiz I amx my signature.

DONALD J. CAMPBELL.4 

